Abstract: Six sigma is a framework that is used to identify inefficiency so that the cause of inefficiency will be known and right improvement to overcome cause of inefficiency can be conducted. This paper presents result of implementing six sigma to improve piston assembly line in Manufacturing Laboratory, Universitas Indonesia. Six sigma framework will be used to analyze the significant factor of inefficiency that needs to be improved which causes bottleneck in assembly line. After analysis based on six sigma framework conducted, line balancing method was chosen for improvement to overcome causative factor of inefficiency which is differences time between workstation that causes bottleneck in assembly line. Then after line balancing conducted in piston assembly line, the result is increase in efficiency. Efficiency is shown in the decreasing of Defects per Million Opportunities (DPMO) from 900,000 to 700,000, the increasing of level of labor productivity from 0.0041 to 0.00742, the decreasing of idle time from 121.3 seconds to 12.1 seconds, and the increasing of output, which is from 1 piston in 5 minutes become 3 pistons in 5 minutes.
Abstract: Manufacturing process has been considered as one of
the most important activity in business process. It correlates with
productivity and quality of the product so industries could fulfill
customer’s demand. With the increasing demand from customer,
industries must improve their manufacturing ability such as shorten
lead-time and reduce wastes on their process. Lean manufacturing
has been considered as one of the tools to waste elimination in
manufacturing or service industry. Workforce development is one
practice in lean manufacturing that can reduce waste generated from
operator such as waste of unnecessary motion. Anthropometric
approach is proposed to determine the recommended measurement in
operator’s work area. The method will get some dimensions from
Indonesia people that related to piston workstation. The result from
this research can be obtained new design for the work area
considering ergonomic aspect.